Wall Structure with Moisture Diverter and Method of Making Same

ABSTRACT

System and method for making a wall structure which diverts moisture from an opening. The wall structure has a structural member with a horizontal opening. A moisture diverter is secured to the structural member above the opening, the moisture diverter having a first end and a second end and a length, with the diverter length greater than the horizontal opening distance and the first end positioned relatively higher than the second end. The moisture diverter is laterally positioned at least partially over the horizontal opening. The moisture diverter has a first planar portion and a second planar portion attached to the first planar portion, forming an acute angle. A moisture barrier is secured to the structural member, at least in part, within a volume defined by the first planar portion and the second planar portion. A facade member is secured to the structural member distal of the moisture barrier.

RELATED APPLICATION

This application claims prior from provisional U.S. Patent ApplicationNo. 61/090,763, Koester, Moisture Diverter, filed Aug. 21, 2008.

FIELD

The present invention relates generally to devices, systems and methodsof making a wall structure, and in particular a wall structure with amoisture diverter.

BACKGROUND

Wall structures for many different types of buildings commonlyincorporate two or more layers of materials in order to achieve thetypical goals of providing relative isolation between the interior ofthe building and the exterior of the building, of maintaining thestructural integrity of the building, and of providing decoration. As istypically the case, the basic component of a wall structure may be astructural member, either load-bearing or otherwise, onto which otherbuilding materials may be secured. Facade members which may primarilyserve a decorative function may be secured on the outside of thestructural member. Facade members may also provide isolation between theinterior of the building and the exterior of the building, by providinginsulation and water impermeability. Even if the facade member isrelatively impermeable to water, a moisture barrier may commonly bepositioned between the structural member and the facade member in orderto prevent moisture (liquid or vapor) which penetrates the facade memberfrom coming into contact with the structural member, which may thenprevent rot or mold. Other materials are also commonly utilized inbuilding wall structures.

In one sense, it may be preferable to build wall structures with nointerruptions or variations within the structure. By making wallstructures uniform, water which contacts the exterior of the wallstructure may tend to run down the facade member or the moisture barrierevenly and uniformly. Moreover, without interruptions, a constantmoisture barrier may be effective in preventing most or all water whichcontacts the wall structure from coming into contact with the structuralmember. In general, the less water which comes into contact with thestructural member, the less rot or mold the structural member mayexperience and the longer the structural member may tend to retain theability to support the wall structure as a whole without replacement,which may be expensive or necessitate replacing the entire wallstructure.

However, it is often desirable to provide openings in wall structuresfor door, windows, ventilation, and other functions. Such openingscreate non-uniformities in the wall structure, which inherently createopenings in the moisture barrier. These openings in the moisture barriermay tend to expose the structural member to water from outside thebuilding. While various treatments and articles have been created tomitigate the introduction of water to the structural member arising fromopenings on the moisture barrier from openings in the wall structure,relatively large amounts of water which contact the wall structure in ashort period of time, such as during rain, may exceed the capacity ofthe treatments or articles to prevent undesirable amounts of watercontact with the structural member.

SUMMARY

A wall structure has been developed which may reduce the potential foran opening in the wall structure to result in moisture contact with thestructural member. A sloped moisture diverter may be positioned abovethe opening, with the facade member and the moisture barrier positionedoutside of the sloped moisture diverter relative to the structuralmember. The moisture diverter may be wider than the opening, such thatwhen moisture runs down the facade member or the moisture barrier thewater contacts the sloped moisture diverter rather than simply cominginto contact with the opening.

Because the moisture diverter is sloped and wider than the opening, themoisture may run down the moisture diverter, exiting the moisturediverter past the opening. Once the moisture falls off the moisturediverter it may continue down the wall structure, in the facade memberor in contact with the moisture barrier, without the structural memberbeing exposed to the moisture. As such, stress on the treatments orarticles protecting the structural member around the opening may bereduced, and the structural member may be less prone to rot and decay.

In an embodiment, a method of making a wall structure formed of astructural member forming a horizontal opening having a horizontalopening distance and an opening top is disclosed. A moisture diverter issecured to the structural member above the opening, the moisturediverter having a first end and a second end and a diverter lengthbetween the first end and the second end, the diverter length beinggreater than the horizontal opening distance, the first end beingpositioned relatively higher than the second end, and the moisturediverter being laterally positioned at least partially over thehorizontal opening and proximate the opening top. The moisture divertercomprises a first planar portion a second planar portion attached to thefirst planar portion and forming an acute angle therewith. The moisturediverter is impermeable to liquid. A moisture barrier is secured to thestructural member, at least in part, within a volume defined by thefirst planar portion and the second planar portion. A facade member issecured to the structural member distal of the moisture barrier.

In an embodiment, the facade member is positioned, at least in part,distal of the moisture diverter relative to the structural member

In an embodiment, the facade member is positioned, at least in part,within the volume defined by the first planar portion and the secondplanar portion.

In an embodiment, the moisture diverter is secured with the first endbeing approximately one-quarter inch higher than the second end forevery foot of length of the diverter length.

In an embodiment, the moisture diverter is secured with a midpoint ofthe moisture diverter being laterally coincident with a midpoint of thehorizontal opening.

In an embodiment, a wall structure comprises a structural member, amoisture diverter, a moisture barrier and a facade member. Thestructural member forms an opening having a horizontal distance and anopening top. The moisture diverter, impermeable to liquid, is secured tothe structural member above the opening and proximate the opening top.The moisture diverter comprises a first planar portion and a secondplanar portion attached to the first planar portion and forming an acuteangle therewith. The moisture diverter has a first end, a second end anda diverter length between the first end and the second end, the diverterlength being greater than the horizontal opening distance, the first endbeing positioned relatively higher than the second end, and the moisturediverter being laterally positioned at least partially over thehorizontal opening. The moisture barrier is secured to the structuralmember and distal, at least in part, of the first planar portionrelative to the structural member. The facade member is coupled to thestructural member distal of the moisture barrier relative to thestructural member.

DRAWINGS

FIG. 1 is a cutaway view of a wall structure with a sloped moisturediverter;

FIG. 2 is a schematic drawing of the moisture diverter of FIG. 1;

FIG. 3 is profile view of the wall structure of FIG. 1; and

FIG. 4 is a flowchart for building the wall structure of FIG. 1.

DESCRIPTION

The entire contents of provisional U.S. Patent Application No.61/090,763, Koester, Moisture Diverter, filed Aug. 21, 2008, isincorporated herein by reference.

Structural members of wall structures may be relatively vulnerable toexposure to water, which may create rot or decay. Moisture barriers havebeen created to prevent water from coming into contact with thestructural member. Creating openings in wall structures for doors,windows, ventilation or other functions is desirable but also createspoints of relative weakness where structural members of the wall may beparticular vulnerable to exposure to water. A wall structure whichdiverts moisture from openings in the wall structure has been created,thereby potentially reducing the amount of moisture which flows to theopening in the wall structure and reducing the potential exposure of thestructural member to moisture.

FIG. 1 is a cutaway view of wall structure 10. Structural member 12, inan embodiment conventional exterior sheathing well known in the art, iscombined with a conventional structural support, in an embodiment astandard dimensional lumber to a metal stud, to support, at least inpart, wall structure 10. In various common embodiments, it isimpractical, particularly for cost reasons, to treat structural member12 such that structural member is impervious to moisture. As such, themore moisture which comes into contact with structural member 12, themore likely structural member may be to rot and decay.

In the illustrated embodiment, moisture control member 16 is attached tostructural member 12 in order to drain from the wall structure moisturewhich may enter the wall structure, for example, either throughcondensing water vapor or liquid water. Moisture control member 16 maybe made from several different materials, including combinations ofmaterials. Moisture control member 16 may be that member described inU.S. Pat. No. 6,990,775, Koester, Moisture Draining Product, Wall SystemIncorporating Such Product and Method Therefore, which is herebyincorporated by reference in its entirety. As illustrated in FIG. 1,moisture control member 16 includes two layers of asphalt impregnatedconstruction paper 18 and drainage member 20 of Sure Cavity™ drainagematerial made by Masonry Technology, Inc. Moisture control member 16 maybe configured such that moisture which comes into contact from theoutside of wall structure 10 may drain from the wall structure bydraining down moisture control member 16 and past structural member 12.

Facade member 22 may be positioned outside of moisture control member16. Facade member 22 may provide both aesthetic benefits to wallstructure 10 as well as moisture control intended to reduce or preventliquid water or water vapor from entering the wall structure from theexterior and provide additional protection against weathering and otherdamage. Facade member 22 may be many different materials commonly knownin the art, including wood, stone, and brick. As illustrated, facademember 22 is primarily comprised of stucco 24, as illustrated comprisingthree layers. Metal lath 26 is secured to structural member 12,whereupon stucco 24 may be applied to lath 26 to secure the stucco towall structure 10. In the case of stucco, stone or brick, an additionalwater impermeable barrier may be used between the stucco, stone or brickto provide moisture impermeability.

Opening 28, as illustrated window 30, may be formed in wall structure10. Conventionally, opening 28 may be formed simply by selectingappropriately sized materials for structural member 12, moisture controlmember 16 and facade member 22. Alternatively, opening 28 may be cutinto wall structure 10 by cutting through the various layers 12, 16, 22.As is well known in the art, openings 28 may also be doors, ventilators,or other common openings. Window 30 may conventionally be secured andaffixed in wall structure 10 by securing devices, metal termination 34,caulking 36 and backer rod 38.

Wall structure 10 further includes sloped moisture diverter 40. Slopedmoisture diverter 40 may be made from conventional metal sheeting, in anembodiment galvanized steel. Sloped moisture diverter 40 may includefirst planar portion 42 and second planar portion 44. Combined, firstplanar portion and second planar portion combine to form channel 46. Bypositioning first planar portion 42 between moisture control member 16and structural member 12, moisture which runs down moisture controlmember 16 may drip into channel 46 of sloped moisture barrier 40.

In an embodiment, sloped moisture barrier 40 has first end 48 and secondend 50 defining a length of moisture barrier 40. In an embodiment,opening 28 likewise has a first end 52 and a second end 54 defining ahorizontal width or distance of opening 28. In an embodiment, slopedmoisture diverter 40 may be positioned above and proximate opening top29 of opening 28 such that each end 48, 50 of sloped moisture diverter40 projects four inches beyond each end 52, 54 of opening 28. Inaddition, sloped moisture diverter 40 may be positioned such that forevery foot of length of sloped moisture diverter 40, first end 48 isone-quarter inch higher than second end 50. In alternative embodiments,second end 50 is positioned higher than first end 48. As such, slopedmoisture diverter 40 length may be selected in order to meet thosecriteria relative to the horizontal width or distance of opening 28.

In alternative embodiments, the four inch projection of ends 48, 50beyond ends 52, 54, respectively, may be varied, and the one-quarterinch per foot slope characteristic may be varied, depending on theparticular circumstances, particularly relating to an amount of moisturewhich may be expected to contact wall structure 10 and the conditions inwhich the moisture may contact wall structure 10. In circumstances whererelatively high winds may tend to blow large amounts of rain againstwall structure 10, it may be desirable to increase the slope of slopedmoisture diverter 40 while increasing the overall length of moisturediverter 40 in order to divert relatively greater amounts of water awayfrom opening 28 relatively more quickly.

FIG. 2 is a schematic drawing of sloped moisture diverter 40. In anembodiment, first planar portion 42 is one and seven-eighths inches talland second planar portion 44 projects five-eighths inches beyond firstplanar portion 42. In an embodiment, second planar portion 44 is angledat 65 degrees relative to first planar portion 42. In an embodiment, thematerial of sloped moisture diverter 40 may be 0.024 inches thick. Inalternative embodiments, these dimensions may be altered. In particular,second planar portion 44 may be angled at greater or lesser angles andmay project greater or lesser amounts from first planar portion 42. Suchdiffering dimensions may be selected on the basis of the conditions inwhich sloped moisture diverter 40 are going to be used. If relativelylarge amounts of moisture may be expected to drain into sloped moisturediverter 40 then first planar portion 42 and second planar portion 44may be selected such that channel 46 is relatively larger. If relativelylittle moisture is expected then first planar portion 42 and secondplanar portion 44 may be selected such that channel 46 is relativelysmaller.

FIG. 3 is a side-view of wall structure 10. Moisture control member 16and sloped moisture diverter 40 may be affixed to structural member 12.As illustrated, asphalt impregnated construction paper 18 may be made intwo parts, with first planar portion 42 positioned between top part 56and structural member 12, and bottom part 58 positioned between slopedmoisture diverter 40 and structural member 12. As illustrated, drainagemember 20 may be positioned within channel 46. In alternativeembodiments, drainage member 20 may be positioned outside of channel 46,at least in part.

As illustrated, facade member 22 is positioned outside of channel 46. Inalternative embodiments, facade member 22 may be positioned inside ofchannel 46, at least in part. In an embodiment, metal lath 26 and atleast one layer of stucco 24 may be positioned within channel 46. Insuch an embodiment, sloped moisture diverter 40 may provide structuralsupport to facade member 22. Such structural support may be improved byincreasing the size of first planar portion 42 and second planar portion44, to provide greater contact area with facade member 22 and structuralmember 12, thereby potentially improving an ability to secure slopedmoisture diverter 40 to structural member 12 and a support area withfacade member 22.

FIG. 4 is a flowchart for creating wall structure 10. Structural member12 may be constructed (400). Moisture control member 16 may be secured(402) to structural member 12 and sloped moisture diverter 40 may beobtained (404) and secured (406) with first planar portion 42 tostructural member 12 in a manner consistent with the structure of FIGS.1 and 3. In an embodiment, sloped moisture diverter is secured tostructural member such that end 48 is one-quarter inch higher than end50, and ends 48, 50 extend four inches beyond ends 52, 54 of opening 28.

Securing (402) moisture control member 16 and securing (406) slopedmoisture diverter 40 may occur concurrently or in sequence. The stepsmay occur concurrently particularly to create wall structure 10consistent with the embodiment of FIG. 3, in which case bottom part 58of moisture control member 16 may be secured to structural member 12,followed by sloped moisture barrier 40, followed by top part 56 ofmoisture barrier.

Facade member 22 may then be secured (408) to structural member 12.Optionally, opening 28 may be formed (410) in order to permit theinsertion of window 30. Alternatively, and in an embodiment preferably,opening 28 is formed during steps (400), (402), (406) and (408) byselecting building materials such that opening 28 does not have to becut in wall member 10.

Various modifications and alterations of this invention will be apparentto those skilled in the art without departing from the scope and spiritof this invention. It should be understood that this invention is notlimited to the illustrative embodiments set forth above.

1. A method of making a wall structure formed of a structural memberforming a horizontal opening having a horizontal opening distance and anopening top, comprising the steps of: securing a moisture diverter tosaid structural member above said opening, said moisture diverter havinga first end and a second end and a diverter length between said firstend and said second end, said diverter length being greater than saidhorizontal opening distance, said first end being positioned relativelyhigher than said second end, and said moisture diverter being laterallypositioned at least partially over said horizontal opening and proximatesaid opening top, said moisture diverter comprising: a first planarportion; and a second planar portion attached to said first planarportion and forming an acute angle therewith; said moisture diverterbeing impermeable to liquid; and securing a moisture barrier to saidstructural member, at least in part, within a volume defined by saidfirst planar portion and said second planar portion; and securing afacade member to said structural member distal of said moisture barrier.2. The method of claim 1 wherein said facade member is positioned, atleast in part, distal of said moisture diverter relative to saidstructural member
 3. The method of claim 1 wherein said facade member ispositioned, at least in part, within said volume defined by said firstplanar portion and said second planar portion.
 4. The method of claim 1wherein said securing a moisture diverter step secures said moisturediverter with said first end being approximately one-quarter inch higherthan said second end for every foot of length of said diverter length.5. The method of claim 1 wherein said securing a moisture diverter stepsecures said moisture diverter with a midpoint of said moisture diverterbeing laterally coincident with a midpoint of said horizontal opening.6. A wall structure, comprising: a structural member forming an openinghaving a horizontal distance and an opening top; a moisture diverter,impermeable to liquid, secured to said structural member above saidopening and proximate said opening top, said moisture divertercomprising: a first planar portion; and a second planar portion attachedto said first planar portion and forming an acute angle therewith; saidmoisture diverter having a first end and a second end and a diverterlength between said first end and said second end, said diverter lengthbeing greater than said horizontal opening distance, said first endbeing positioned relatively higher than said second end, and saidmoisture diverter being laterally positioned at least partially oversaid horizontal opening; a moisture barrier secured to said structuralmember and distal, at least in part, of said first planar portionrelative to said structural member; a facade member coupled to saidstructural member distal of said moisture barrier relative to saidstructural member.
 7. The wall structure of claim 6 wherein said facademember is positioned, at least in part, distal of said moisture diverterrelative to said structural member
 8. The wall structure of claim 6wherein said facade member is positioned, at least in part, within avolume defined by said first planar portion and said second planarportion.
 9. The wall structure of claim 6 wherein said a moisturediverter is positioned said first end being approximately one-quarterinch higher than said second end for every foot of length of saiddiverter length.
 10. The wall structure of claim 6 wherein said moisturediverter is secured with a midpoint of said moisture diverter beinglaterally coincident with midpoint of said horizontal opening.